Electrical connector



Filed Sept. 16, 1950 3 Sheets-Sheet 1 2 3 J. c. MACY 2 2 ELECTRICAL.CONNECTOR I N VEN TOR.

James C Macy BY A TTOIZIVEYS Feb. 24, 1953 J. c. MACY 2,629,753

ELECTRICAL CONNECTOR Filed Sept. 16, 195a s Sheets-Sheet 2 E filin Feb.24, 1953 J. c. MAcY 2,629,763

I ELECTRICAL CONNECTOR Filed Sept. 16, 1950 s Sheets-Sheet s INVENTOR 68J6 JIM/ax: 6 Ma ATTORN Y5 Patented Feb. 24, 1953 2,629,763 ELECTRICALooNNEo'roR J a Ma W s fieid, N. J., a i nor o A craft-Marine ProductsInc., Harrisburg, Pa,

Appiication September 16, 1950, Serial No. 185,221

2 Claims.

This invention relates to connectors for wires, cables and the like andparticularly to improvements in connectors of the type which comprisecounterpart terminals having respectively, when connected, interengagingclips.

In the connectors shown in Watts Patent 2,478,1 i3 a blade part of eachterminal is formed by a direct continuation of one side of a ferrule bywhich the respective terminal is secured to and electrically connectedwith a wire; and the clip part of each of the terminals is formed froman integral lateral extension of the blade and is of substantiallyuniform width. Since the two terminals have to be brought into anangular relation to each other when assembling, the clip designnecessitates a somewhat greater spacing of the clip part of eachterminal from the ferrule thereof than the mere width of said clip inorder to permit the angular movement of the terminals required for theinterengaging of the two clips and blades. The present invention has asone object the reduction of this excess length with correspondingreduction in weight and expense.

The present invention further aims to provide an improvedconnectorconstruction which, without undue increase in length, will provide astop for the end of the conductor or cable, etc., inserted in theferrule; andwhich will also-prevent substantial endwise movement of theterminals 0 relative to each other when in their assembled condition;and which will also providea rubbed pressure contact which both improveselectrical conduction and adds security to the mechanical connection.

The invention aims further to provide a construction of the terminalssuch that, in their assembled condition, their ferrules and the enclosedconductor ends can be in substantially .axial alignment with, or otherdesired relation to, each other, thus making a better appearance andrequiring 1ess spaceat the connection than would be the case if theywere substantially ofiset laterally.

Other objects and important features of the invention, to whichreference has not been made hereinabove, will appear in the followingdescription and claims.

Although in the accompanying drawings 1 have shown a preferredembodiment of myin; vention and have described the same and variousmodifications thereof in this specification, .it is to be understoodthat these are notintended to be either exhaustive or limiting of theinvention, but, on the contrary, are chosen forthepurposes 2 ofillustrating the invention in order that others skilled in the art mayso fully understand the invention, its principles and the applicationthereof, that they may embody it and adapt it in numerous forms, each asmay be best suited to the requirements of its particular use.

In the accompanying drawings:

Figure l is a side elevation of a pair of connectors embodying thepresent invention in assembled or interconnected condition;

Figure 2 is a plan view;

Figure 3 is a section on the line t 3 of Figure 1;

Figure 4 is a view similar to Figure l of a modified form or theinvention;

Figure 5 is a view similar to Figure 2 but of the connectors shown inFigure l;

Figure 6 is a side elevation of a connector illustrating anotherembodiment of the invention;

Figure 7 is a view of the connector of Figur 6 taken looking upwardlyfrom below;

Figure 8 is a side elevation of a pair of connectors of the embodimentshown in Figure 6 but after they have been crimped onto conductors andas they appear when being interconnected;

Figure 9 is a side elevation of the connectors of Figure ,8 when fullyinterconnected and also showing part of a length of insulating tubingenv o i th o ne tio Figure 10 is a view of the connectors of Figure 9taken looking upwardly from below;

Figure 11 is a view similar to thatof Figure 6 but showing still anotherembodimentpf the invention;

Figure i2 is a view of the connector of Figure .1 take leas n pw d frombelow;

Figure l3 is a viewf'sii'nilarto that of Figure 11 but showing theconnector crimped onto a conu l. H V

Figure 14 is a perspective view of another form of terminal embodyingthe invention;

Figure i5 is a side view of the terminal shown in Figurelginterconnected with a connector of the typeillustrated in Figure 8;Figure i6 is a perspective view of yet another form of connector elementembodying the in,-

vention;

Figure 17 is a view partly in section illustrating multiple fi i nitembodying the invvention ;v and Figure 18 is a viewsimilar to that ofFigure 17 but illustrating a different partial cross section through theunit.

In the firstillustrative embodiment of them-- vention, each of theterminals of the present invention is a counterpart of the other andcomprises a ferrule 2, and a tongue or blade portion 4 extending fromone side of said ferrule but bodily offset to bring the respectiveferrules of the two connectors into alignment. This leaves a bent-overor shoulder portion 6 extending over the outer end of the ferrule. Theblade portion 4 of each terminal has an integral extension bent over theend of the tongue to form the clip 8, the blade portion 4 of eachterminal acting as a receptor which is received between the blade andclip portions of the other terminal in the assembled connection.

The maximum width of the clip 8 on each terminal is at leastsubstantially equal to or only slightly less than the distance betweenthe inner edge of the clip 8 and the shoulder or abutment 6 so that,when the two terminals are in the assembled relation shown in Figure 1,the clip of one will fit substantially between the clip 8 of the otherterminal and the shoulder 6 thereof. The end of the blade 4 and/or theclip 8 is curved, as shown at I0, so that it can cam against theshoulder 6 of the other connector to bring the parts into the intendedrelation when they are swung from perpendicular to aligned relation. Theshoulder 6 serves to limit passage of wire beyond the ferrule 2 so as toprevent interference by such wire with the proper interconnection of theterminals.

As in the connector of the Watts patent hereinabove referred to,connection or disconnection of the two terminals which make u theconnection requires movement thereof into an angular relation (se alsoFigure 8), approximately perpendicular relation in the case shown,before they can either be connected or disconnected. It will be seenthat disconnection cannot be effected merely by an endwise pull or by anendwise push or by any ordinary lateral strain and that therefore theterminals are securely interlocked against unintentional separation.

The clip 8 adjacent the bend where it is attached to the blade 4 isspaced a distance accurately equal to the thickness of the blade. Beyondthe bend the blade and clip normally converge so that, when assembled asshown in Figure 3, the blade is gripped with a compressive forceresulting from deflection of the clip 8. This aspect of the constructionis more particularly described and is claimed in the Watts patentaforementioned.

If the length of the clip 8 and the form of the cam face [0 areaccurately controlled, the cam face will make pressure contact againstthe shoulder 6 sufficient to scrape into the oxide surface layer andgive a low resistance electrical connection. This arrangement, which isshown in Figures 4 and 5, has the further advantage that the cam firstsprings the shoulder bend 8a and then, as the point l2 of longest radiusmoves in from the edge, the resilient pressure on the cam holds theconnectors latched together.

With the arrangement shown in Figures 4 and 5 it is important to havethe blade 4a and the bend at which it joins the ferrule accuratelyformed, so that no part of the bend tends to hold the clip 8a away fromthe blade. To this end the edges of the clip and/or blade are rounded asindicated at 14. With space allowed, as shown in Figures 1 and 2, theforming at the bend can be less exact. In any event the bend sets alimit to the extent to which the cylindrical conformation of ferrule 2may merge into and run along the blade portion. If good face-to-facecontacts between clip and blade faces of two interconnected terminalsare to occur then the receptor part of the blade should be planar, andfree of any merging into cylindrical shape adjacent the ferrule as mayoccure with the unbent terminal disclosed in the Watts patent.

The clip is shown in Figures 4 and 5 on the same side of its blade asthe shoulder 6a formed by the bend in the blade. This has the advantagesof bringing the cam pressure directly on the end of the blade, and ofbringing the shoulder 6a farther across the end of the ferrule 2 to givea more effective stop for limiting insertion of a wire therein. With therelationship illustrated in Figure 5 the two aligned clips are heldunder a slight lengthwise compression between shoulders 6a; thiscompression tends to maintain the locked relationship because, ineffect, the parts have been moved past a dead center across which theymust be returned to permit unlocking. At the exact dead centerlengthwise compression on the clips between shoulders 6a is, of course,a maximum. A satisfactory connection is made, however, with the clipbent to the opposite side, as shown in Figures 1-3.

Another embodiment of the invention is illustrated in Figures 6-10. Asbest shown in Figures 6 and 7, the terminal includes a blade portion 20provided at its outer end with a clip 22 and at its inner end with ashoulder portion 24. In this embodiment the ferrule, generally indicatedby 25, is of the composite laminated construction disclosed and claimedin Buchanan Patent 2,379,567. It comprises a split cylindrical ferrulepart 26 integral with shoulder portion 26 and a thin cylindricalseamless sleeve 28 of suitable metal, such as copper, telescoped overthe split cylindrical ferrule part with a snug fit as shown which holdsthe pieces in permanent assembly. The cylindrical sleeve 28 extendsbeyond the ferrule part 26, to the left as viewed in Figures 6 and 7, soas to be in a condition to embrace a substantial end portion of theinsulation sheath of the conductor to which the terminal is latercrimped, as illustrated in Figures 8 and 9. In the illustrativeembodiment of Figures 6-10 the seamless sleeve 28 per se is of the typedescribed and claimed in Carlson et al. Patent 2,405,111 and preferablyis made by the process described and claimed in Carlson et al. Patent2,468,169.

The end of the clip is provided, as by a swedging operation, with aregion of clearance 30. The purpose of this region of clearance is forfacilitating easy assembling of two terminals (see Figure 8). As pointedout in Watts Patent 2,478,143 and also in the description above of theterminal of Figures 1-3, the distance (see Figure 7) from the lowermostsurface of overhanging clip 22 to the opposing upper surface defined bythe outer end of blade portion 20 is less than the thickness of theblade. So when two terminals are properly interconnected the shank orreceptor part of the blade of one terminal will be grasped between theclip and the outer end of the blade of the counterpart terminal. Theclearance region 30 facilitates assembling two counterpart terminalsbecause it enables the receptor part of the blade of one terminal tomake an easier entrance into the receptacle-forming space between theclip and the outer end of the blade of the counterpart terminal. Aspointed out above, face-to-face contact can best be accomplishedif theblade portion ,4, 20, etc., be-

tween the shoulder and clip which for-ms the receptor part of theterminal is maintained in planar condition. The receptor part of theblade is assured a planar condition by the abrupt bend which forms theshoulder because the bend not only eliminates any merging of thecylindrical configuration oi the ferrule into the receptor part but alsoinjects a region which may bend first under forces perpendicular to theplanar faces of the receptor so that the receptor tends to remain flateven during prolonged hard use.

In Figure 8 a pair of terininals are illustrated one being crimped ontothe end of an insulated electrical conductor 32 and the other beingcrimped onto the end of an insulated electrical conductor 3Q. It is tobe observed in each instance that the end of the seamless sleeve 23which extends beyond the ferrule part 26 is telescoped over the end ofthe insulation sheath of the electrical conductor and there compressedin place so as to form an insulation support. The other end of thecylindrical sleeve 28 along with ferrule part 25 is crimped solidly onthe stripped end of the electrical conductor so as to make a permanentelectrical contact. The type of crimped connection illustrated in Figure8 is the one impressed by the normal use of the tool disclosed andclaimed in Carlson Patent 2,359,083, which simultaneously secures theinsulation-supporting part of the ferrule over the end of the insulationsheath of the conductor and permanently crimps the contact-forming partof the ferrule to the stripped end'of the electrical conductor.

Figure 9 illustrates the present invention embodied in a pair ofinterconnected terminals enclosed within a removable piece of seamlessinsulating tubing 3% similar to that illustrated in Figure 1 of WattsPatent 2,478,143. It will be appreciated that when a piece of seamlesstubing is slipped over a pair of interconnected terminals, extendingfrom one end of the interconnection to the other, it is not possible tomove the terminals from the relationship illustrated in Figure 9 intothe relationship illustrated in Figure 8, and accordingly that theterminals must remain locked together so long as the tubing is in place.In order so to lock the terminals -the length of tubing is slipped overone of the terminals to a location along the length of the electricalconductor and the terminals are then interconnected in the ordinarymanner (see for example Figure 8). Thereafter the length of tubing isslipped along the electrical conductor toward the connection until itembraces both of the interconnected terminals within it.

It is to be observed that when a terminal is crimped as illustrated ontothe end of an electrical conductor, the crimped contact-forming portionof the ferrule which includes the ferrule part 26 has the greatestoveralltransverse width of any portion of the terminal. If theinsulating tubing is of the semi-elastic type commonly employed forinsulation, such as an extruded vinyl chloride compound tubing, whichinherently tends to assume its original circular cross section wheneverflattened, the ferrule portions of maximum width engage the inner facesof the tubing when the tubing tends to'return from its flattenedconfiguration to circular cross section and thus the flattened ferruleportions oifer a resistance to longitudinal movement of the tubing. To amarked extent this action locks the tubing in position over theconnection.

Figures 11 and 12 illustrate a terminal similar to that illustrated inFigures 6 and '7 except that in this instance the seamless sleeve 28adoes not extend beyond the ferrule part 26a of the terminal. In thisrespect the terminal resembles the composite laminated ferrule shown inFigure '9 of Buchanan Patent 2,379,567 rather than the one shown inFigure 13 of the Buchanan patent where the sleeve extends to form aninsulation support in the fashion exemplified herein by the embodimentof Figures 6 and '7.

Figure 13 illustrates the connector of Figures 11 and 12 after it hasbeen permanently crimped onto the end of an electrical conductor. As inthe case illustratedin Figure 9, the overall transverse width of theferrule in the region of the contact-forming crimp is seen to be theportion of maximum "transverse'width. This portion resistslongitudinalslippingof an insulating tubing corresponding to the tubing36 described in connection with the embodiment of Figure 9.

It will be understood with respect to each .of the various embodimentsof the invention that the contact-forming crimped portions of the"ferrules will serve to hold a piece of insulating tubing in positionenveloping the interconnectionand that so long as the tubing is heldinpplace the interconnected terminals cannot be disconnected. And ineach instance the shoulder portions 6, 24, 24a, etc., preventappreciable lengthwise movement of one terminal with respect to itscounterpart so that relative longitudinal movement of the interconnectedterminals .cannot work an enveloping insulating tubing 01f .of lockingposition on the connection.

In eachof the foregoing specifically described embodiments of theinvention the terminal has included some formof ferrule. Figure 14 and15 illustrate another typeofterminal generally indicated at 4b. In theembodiment herein described, terminal M3 is formed from sheet metal bymetal stamping andbending operations and embodiesachannel-likeconnecting.end indicated at 42 and a ring tongueend-indicated at MS. Tongue M is intended to be positioned overathreaded binding post in conventional fashion and there locked in placeby anut. Connecting end 62 includes a blade-like portion 36 providedtoward its .outer end with an integral clip 48 bent over'throughapproximately from the upper outer longitudinal edge of the blade.Between blade portion 4'6 and tongue'M the terminal is provided with ashoulder portion to spaced from the nearest edge of clip 48 as measuredlongitudinally along blade portion l-fi by an amount only slightlygreater than thelongitudinal width of the clip.

Thus a connector of the type describedin relation to Figure 8 may beinterconnected with terminal 4i! inthe same manner that the twoconnectors described in relation to Figure8 were interconnected.

When terminals of the type illustrated in-Figures '14 and 15 areavailable, an electrical connector of the preceding types illustratedand described'herein may be brought'into electrical engagement withanordinary binding post so that electrical systems embodying my inventionmayreadily *be'assembled'asparts of larger sys- "tems embodying moreconventional connectors. .It will be appreciated, of course, that theclip, blade portion, and shoulder portion of the terminal illustrated inFigures 14 and 15 perform the same equivalent functions as are performedby the corresponding parts of the connectors previously describedherein.

Figures 16, 17 and 18 illustrate the present invention embodied in amultiple connector block such as is disclosed in Figures 17-21 of myapplication Serial No. 631,031 filed November 27, 1945, now Patent No.2,545,429, issued March 13, 1951; for a more complete disclosure of thistype of multiple connector block reference may be had to saidapplication. The conducting element of the connector block is indicatedgenerally in Figure 16 at 52. Element 52 in the illustrative form isformed from sheet metal by stamping and bending operations andincorporates a central conducting portion 54, a pair of shoulderportions 56 and 58 located at each end of the conducting portion, a pairof blade portions 60 and 62, and at each end of the element an integralclip 64, 65. The clip and shoulder and blade portions of element 52 areshaped to perform the same functions as the clip and shoulder and bladeportions of terminal 40 and of the preceding connectors describedhereinabove. connector of the type illustrated in Figure 8 may beinterconnected at either end of element 52 with the clip of theconnector in face-to-face contact with the blade portion of element 52and constrained against longitudinal movement in either direction alongthe blade portion by the abutting faces presented by the clip and theshoulder portion.

Figures 17 and 18 illustrate the use of a plurality of elements 52locked in parallel disposition within a connector block fashioned frominsulating material. The connector block comprises a central disk 58provided with radial slots, each slot being fitted to receive theintermediate portion 54 of an element 52. As shown in Figure 18 a pairof insulating cores l and 72 are clamped in back-to-back relationshipupon the center of disk 03 by an axially disposed rivet (4. Each ofthese cores is provided with radially extending clearances aligned withthe radially extending slots of disk 68 fitted so as to afford access tothe end portions of the elements 52 and so as to form insulatingbarriers between adjacent end portions. As pointed out in greater detailin my copending application, the intermediate portion 54 of each element52 is molded or otherwise permanently secured within its individualradially extending slot so that its end portions are maintained in fixedposition within the respective fitted clearances provided in cores and72. Thus, as shown for example in Figure 17, the portion 54 of element52 there illustrated is fixedly secured in disk 68 with shoulders 56 and58 in abutment against the opposing flat surfaces of the disk so as toreinforce element 52 against longitudinal movement within the radialslot in which it is held. The end portions of elements 52 function inthe same manner as the end portions of any of the abovedescribedinterconnectors embodying my invention.

The opposing ends of each of the elements 52 may be made accessible, sothat connectors of the type illustrated in Figure 8 for example may beinterconnected with them, by removing the spring clips 76, 78, 80 and 82and disassembling the insulating surrounding semi-cylindrical shellsindicated at 84 and 86. After the connections have been made they may belocked against accidental disconnection or protected against short Thusa circuits by restoring the insulating shells 8| and 86.

From the foregoing it is apparent that the connectors, terminals andconnecting elements de scribed above are well suited to attain the endsand objects herein directly and indirectly set forth, and that they canbe manufactured easily by conventional fabrication techniques, and thatthe various features and arrangements of parts can be modified readilyso as best to suit a particular use. Certain features of the disclosuremay be used to advantage in particular applications without acorresponding use of other features, and the elimination or modificationof such features is to be construed as within the scope of thisinvention unless specifically excluded by the following claims orrequired by the scope of the prior art.

I claim:

1. A connector comprising a ferrule for connection to a circuit element,a strip-like blade of substantially uniform thickness extending freelytherefrom, a clip on a portion of the blade remote from the ferrule, oneface of said blade to ward the free end portion thereof being planar fora distance back from the free end at least about twice the correspondingdimension of said clip, said clip extending integrally from a lateraledge of said end portion and across said planar face with spacingtherefrom which, when the connector is unconnected, is slightly lessthan the thickness of the blade, and a bend on a straight line acrossthe strip-like blade between the ferrule and the end portion forming aguide for engaging the end of a counterpart connector during connectionto hold its clip portion within the region surrounding said planar face.

2. A connector comprising a ferrule having a blade extending from oneend thereof, said blade being bent adjacent the ferrule to offset theremainder of the blade so that one face thereof is substantially on anextension of the axis of the ferrule, a clip on a portion of said bladeremote from the bend, said clip extending from one lateral edge beyondsaid axial face and back across said face with spacing therefrom which,when the connector is free, is slightly less than the thickness of theblade, said clip being formed from an ear extending integral with theblade, extending laterally therefrom and folded back upon the bladethrough at least degrees, and the length of the blade portion betweenthe clip and the bend in the blade adjacent the ferrule being at leastas great as the corresponding dimension of the clip.

JAMES C. MACY.

REFERENCES CITED The following references are of record in the file ofthis patent:

UNITED STATES PATENTS Number Name Date 1,104,436 Menningen July 21, 19141,225,127 Heath May 8, 1917 2,021,701 Smith Nov. 19, 1935 2,450,202 MacySept. 28, 1948 2,453,615 Bergan Nov. 9, 1948 2,478,143 Watts Aug. 2,1949

